Synthetic bone matrix

ABSTRACT

Disclosed is an osteogenic device capable of inducing the formation of endochondral bone in a shape conforming substantially to the shape of the device when implanted in a mammalian host. The device includes an osteogenic protein dispersed within a porous matrix comprising a polymer of collagen and glycosaminoglycan cross-linked to an MC value of about 800 to about 60,000. Also disclosed are a method of inducing mammalian bone growth, and a method of inducing conductive bone growth from viable mammalian bone.

REFERENCE TO RELATED APPLICATIONS

This application is a rule 1.53(b) continuation of U.S. Ser. No.08/443,676, filed May 18, 1995, now U.S. Pat. No. 6,077,988, which is adivisional of U.S. Ser. No. 07/529,852, filed May 29, 1990, now U.S.Pat. No. 5,645,591, the disclosures of which are herein incorporated byreference.

BACKGROUND OF THE INVENTION

This invention relates to osteogenic devices, and more specifically tosynthetic implants which induce osteogenesis in vivo. More particularly,this invention relates to biocompatible, bioresorbable, syntheticmatrices which promote endochondral bone growth in vivo.

The potential utility of an osteogenic device capable of inducingendochondral bone formation in vivo has been recognized widely. It iscontemplated that the availability of such a device would revolutionizeorthopedic medicine, certain types of plastic surgery, and variousperiodontal and craniofacial reconstructive procedures.

The developmental cascade of bone differentiation in mammalian bonetissue is well documented in the art (Reddi (1981) Collagen Rel. Res.1:209-226). Though the precise mechanisms underlying the phenotypictransformations are unclear, it has been shown that the naturalendochondral bone differentiation activity of bone matrix can bedissociatively extracted and reconstituted with inactive residualcollagenous matrix to restore full bone inducing activity (Sampath etal. (1981), Proc. Natl. Acad. Sci. USA 78:7599-7603).

Mammalian bone tissue is known to contain one or more active factor(s)which are proteinaceous materials capable of inducing the developmentalcascade of cellular events resulting in endochondral bone formation.This active factor has variously been referred to in the literature asbone morphogenetic or morphogenic protein, bone inductive protein,osteogenic protein, osteogenin, or osteoinductive protein. Recently, theprotein factors referred to as osteogenic protein (OP) responsible forinducing osteogenesis have been purified, expressed in recombinant hostcells, and shown to be truly osteoinductive when appropriately sorbedonto a matrix. (U.S. patent application Ser. No. 179,406).

Studies have shown that while osteoinductive proteins are active crossspecies, the collagenous bone matrix heretofore required for inducingendochondral bone formation is species specific (Sampath and Reddi(1983) Proc. Natl. Acad. Sci. USA 80:6591-6594). Implants ofdemineralized, extracted xenogenic bone matrix and OP invariably haveresulted in a strong inflammatory response that has inhibitedosteogenesis, presumably due to immunogenic protein components in thebone matrix. Hence, osteoinduction requiring the use of allogenic bonematrix is a serious limitation with respect to human clinical use, ashuman bone is neither readily available nor cost effective.

The current state of the art of materials used in surgical proceduresrequiring conductive bone repair, such as the recontouring or filling inof osseous defects, is disclosed by Deatherage (J. Oral Maxillofac.Surg. (1988) 17:395-359). All of the known implant materials described(hydroxlapatite, freeze-dried bone, or autogenous bone grafts) havelittle or no osteoinductive properties. Clearly, the ability to induceosteogenesis is preferred over bone conduction for most procedures.

U.S. Pat. No. 4,795,467 discloses a bone repair composition comprisingcalcium phosphate minerals and a telopeptide, reconstituted,cross-linked fibrillocollagen. U.S. Pat. No. 4,563,350 discloses anosteogenic device comprising a bone-inducing extract and a collagenousmatrix composed of approximately 90% trypsinized bovine bone matrix and10% bovine dermal collagen. U.S. Pat. No. 4,789,663 discloses a methodof effecting conductive bone repair comprising exposing the defect tofresh bone, and using xenogenic collagen from bone and/or skin, whereinthe collagen is enzymatically treated to remove telopeptides, and isartificially cross-linked. EPO 309,241 discloses a device for inducingendochondral bone formation comprising an osteogenic extract, and amatrix carrier comprising 60-90% mineral component and 2-40% collagen.Deatherage et al., (Collagen Rel. Res. (1987) 7:2225-2231) purports todisclose an apparently xenogenic implantable device comprising a bovinebone matrix extract and Type 1 human skin collagen. Co-pending patentapplication Ser. No. 422,613, filed Oct. 17, 1989, entitled “BoneCollagen Matrix for Xenogenic Implants,” discloses a xenogenic boneimplant prepared from demineralized bovine bone and including osteogenicprotein.

It is an object of this invention to provide a biocompatible,biodegradable bone matrix, implantable in a mammalian host with nosignificant inhibitory immunogenic response. Another object is toprovide a matrix which is biocompatible, biodegradable, and which iscapable of inducing osteogenesis when incorporated with osteogenicprotein in mammals, including humans. Still another object is to promoteconductive bone growth in mammals, including humans. Yet other objectsare to provide a superior material for coating implantable protheticdevices, and to increase the cellular ingrowth into such devices. Yetanother object of the invention is to provide a method for theproduction of such matrix material.

These and other objects and features of the invention will be apparentfrom the description, drawings, and claims that follow.

SUMMARY OF THE INVENTION

It has been discovered that osteogenic protein dispersed within aporous, bioresorbable matrix including collagen and glycosaminoglycan iscapable of inducing osteogenesis in vivo. This knowledge has beenexploited to develop novel osteogenic devices disclosed herein whichinduce the formation of endochondral bone in a mammalian host in a shapeconforming substantially to the shape of the device. The devices mayalso be used as a surface coating for implantable prosthetic devices topromote cellular ingrowth.

The porous matrix of the osteogenic device includes a cross-linkedpolymer of collagen and glycosaminoglycan. Collagen is a major proteinconstituent of connective tissue in vertebrates and invertebrates. TypeI collagen, Type II collagen, or mixtures thereof are preferable as thematrix material of the osteogenic device. Preferably collagen comprisesabout 80-95% by weight of the matrix.

Glycosaminoglycans (GAGs) are mucopolysaccharides of animal origin. Theyare made up of residues of hexosamines glycosidically bound andalternating in a more-or-less regular manner with either hexuronic acidor hexose moietites. GAGs preferably make up at least about 5%, and morepreferably, from about 6% to about 15% by weight of the polymer. UsefulGAGs include those comprising sulfate groups such as chondroitin4-sulfate, chondroitin 6-sulfate, hyaluronic acid, dermatan sulfate,keratan sulfate, heparin, heparan sulfate and combinations thereof.Preferably the matrix includes chondroitin 6-sulfate.

The collagen-GAG polymer is cross-linked to control the solubility andmechanical properties of the matrix. It has been determined thatcross-linking the matrix to an M_(C) value (number average molecularweight between cross-links) of about 800 to about 60,000, and preferablyto an M_(C) of between 5,000 and 10,000, is most beneficial for theosteogenic device.

The invention is embodied as a method of growing bone by conductionincluding contacting a viable mammalian bone with the cross-linkedcollagen-GAG matrix. Bone conduction is the growth of bone from existingviable bone, and involves the migration of osteoblasts from the bone toan area immediately adjacent the bone. In one aspect of the inventionthe matrix material is provided as a coating on an implant placed incontact with viable bone. Useful implants are composed of an inertmaterial such as ceramic, metal, or polymer. In another aspect of theinvention, conductive bone growth is induced from a viable mammalianbone by contacting the bone with matrix material into which has beendispersed a glue in an amount sufficient to solidify the matrix whenimplanted in a mammal or when placed at 37° C. A useful glue is methylcellulose. The matrix solidifies substantially in the shape of theimplanted matrix.

In an alternative embodiment, osteogenic protein is dispersed within theporous matrix. Osteogenic protein comprises a pair of subunitsconstituting a stable dimer under oxidizing conditions. The protein maybe produced using recombinant DNA techniques or may be an extract ornaturally sourced purified material. In a preferred aspect, one of thesubunits of this protein has an amino acid sequence sufficientlyduplicative of the amino acid sequence of OP1, disclosed herein, suchthat the subunit, when in combination with a second suitable subunitunder oxidizing conditions, induces endochondral bone in a mammal whendisposed within said matrix implanted in the mammal. OP1 is a proteinsubunit having the amino acid sequence set forth below.

1       10        20        30        40STGSKQRSQNRSKTPKNQEALRMANVAENSSSDQRQACKK        50        60        70        80HELYVSFRDLGWQDWIIAPEGYARYYCEGECAFPLNSYMN        90       100       110       120ATNHAIVQTLVHFINPETVPKPCCAPTQLNAISVLYFDDS        130 SNVILKKYRNMVVRACGCH

When OP1 is dimerized to form a homodimer or a heterodimer with certainother protein sequences, it can induce endochondral bone formation.

Another aspect of this invention involves methods of producing theosteogenic device which contains osteogenic protein. The method includesproviding a porous matrix comprising a polymer of collagen and GAGcross-linked to an M_(C) value of about 800 to about 60,000; anddispersing within the matrix an osteogenic protein in an amountsufficient to induce endochondral bone formation substantially in theshape of the matrix when implanted in a host.

The dispersing step may include dispersing the osteogenic protein in asolvent such as buffered saline or acetonitrile. If insoluble collagenis to be incorporated into the matrix, it, too, may be dispersed in thesolvent. In one aspect of the invention, the solvent is an acidified,aqueous solution containing about 30% to about 55% acetonitrile, andpreferably about 50% acetonitrile. The dispersion step may be conductedby dehydrating a mixture including the osteogenic protein and particlesof the collagen-GAG polymer. Alternatively, the dispersing step may beaccomplished by lyophilizing the mixture. Lyophilization is dehydrationof frozen material under vacuum.

Prior to the dispersing step, the matrix may be pre-equilibrated withthe solvent in which the osteogenic protein has been dispersed. Themethod may further include the steps of forming the product of thedispersion step into a shape with predetermined dimensions; andimplanting the formed product into a mammal. Implantation of the deviceresults in the induction of endochondral bone having essentially theshape of the formed product.

Lastly, the invention is embodied as a method of inducing endochondralbone growth in a mammal comprising the step of implanting in the mammal,either surgically or otherwise, at a location where bone formation isdesired, porous matrix material containing dispersed osteogenic proteinof a nature described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects of the invention, the various featuresthereof, as well as the invention itself, may be more fully understoodfrom the following description when read together with the accompanyingdrawings in which:

FIG. 1 is a photomicrograph of a collagen-GAG implant without osteogenicprotein showing the infiltration of only mesenchymal cells; and

FIG. 2 is a photomicrograph of a collagen-GAG matrix includingosteogenic protein showing the presence of osteoblasts (arrows), boneformation, and vascular invasion.

DETAILED DESCRIPTION

This invention provides an osteogenic device capable of inducing de novoosteogenesis when implanted in the mammalian body. The device enabledand disclosed herein will permit the physician to obtain optimalpredictable bone formation to correct, for example, acquired andcongenital craniofacial and other skeletal or dental anomalies (Glowackiet al. (1981) Lancet 1:959-963). The device may be used to induce localendochondral bone formation in non-union fractures and in other clinicalapplications including periodontal applications where bone formation isrequired. Other potential clinical applications include contouraugmentation, spinal fusion, and orthopedic reconstructive surgury.

The osteogenic device useful for inducing de novo bone growth comprisesosteogenic protein dispersed within a cross-linked matrix of collagenand GAG polymers. Osteogenic protein may be obtained using the methodsdisclosed in U.S. patent application Ser. No. 179,406, filed Apr. 8,1988 (entitled “Osteogenic Protein”); PCT application No. US89/01469(entitled Biosynthetic Osteogenic Proteins and Osteogenic DevicesContaining Them), and PCT Application No. US89/01453, (entitled“Osteogenic Devices”). Both PCT applications were filed Apr. 7, 1989.Alternatively, extracts rich in osteogenic protein useful in fabricatingdevices may be obtained as disclosed in U.S. Pat. No. 4,294,753 toUrist. The disclosure of these documents is incorporated herein byreference. Alternatively, any other proteins with osteogenic activity inmammals may be used. Further, skilled genetic engineers can isolategenes from CDNA or genomic libraries which encode appropriate amino acidsequences, or construct DNAs from oligonucleotides, and then can expressthem in various types of host cells, including both procaryotes andeucaryotes, to produce large quantities of active proteins capable ofinducing bone formation in mammals including humans.

The matrix material is composed of collagen polymers andglycosaminoglycans. It may be prepared essentially as described byYannas et al. in U.S. Pat. Nos. 4,280,954 and 4,448,718, the teachingsof which are herein incorporated by reference. Alternatively, theGAG-collagen porous matrix material may be commercially obtained. Forexample, porous microcarriers of collagen-GAG cross-linked copolymerintended for in vitro use (Informatrix™) are available from the BiomatCorporation (Belmont, Mass.). This material was developed originally formedical wound dressing applications, and includes collagen extractedfrom bovine hide, and 8% (w/w) chondroitin 6-sulfate. Other GAG species,such as heparin or hyaluronic acid, can be incorporated on a custombasis.

Briefly, collagen is a major protein constituent of connective tissueand has been widely used in various medical and surgical applicationssuch as for surgical protheses and graft fabrication. This protein iseasily resorbed due to its susceptibility to proteolytic digestion bycollagenases present at the implantation site. It may be in the form ofmacroscopic fibers which can be chemically and mechanically separatedfrom non-collagenous tissue components. Collagen derived from any sourceis suitable for use with this invention, including insoluble collagen,acid-soluble collagen, collagen soluble in neutral or basic aqueoussolutions, as well as those collagens which are commercially available.Typical animal sources include calfskin, bovine achilles tendon, cattlebones, and rat tail tendon.

Glycosaminoglycans (GAGs) or mucopolysaccharides arehexosamine-containing polysaccharides of animal origin. Chemically, GAGsare made up of residues of hexosamines glycosidically bound andalternating in a more-or-less regular manner with either hexuronic acidor hexose moieties (see, e.g., Dodgson et al. in Carbohydrate Metabolismand its Disorders (Dickens et al., eds.) Vol. 1, Academic Press (1968)).Useful GAGs include hyaluronic acid, heparin, heparan sulfate,chondroitin 6-sulfate, chondroitin 4-sulfate, dermatan sulfate, andkeratan sulfate. Other GAGs are suitable for forming the matrixdescribed herein, and thoses skilled in the art will either know or beable to ascertain other suitable GAGs using no more than routineexperimentation. For a more detailed description of mucopolysaccharides,see Aspinall, Polysaccharides, Pergamon Press, Oxford (1970).

Collagen can be reacted with a GAG in aqueous acidic solutions. Thesereactions can be carried out at room temperature. Typically, smallamounts of collagen, such as 0.3% by weight, are dispersed in a diluteacetic acid solution and thoroughly agitated. The GAG is then slowlyadded, for example dropwise, into the aqueous collagen dispersion, whichcauses the coprecipitation of collagen and GAG. The coprecipitate is atangled mass of collagen fibrils coated with GAG. This tangled mass offibers can be homogenized to form a homogeneous dispersion of finefibers and then filtered and dried. The conditions for maximumattachment of GAGs to collagen without significant partial denaturation(gelatinization) were found to be a pH of about 3 and a temperature ofabout 37° C. Although these conditions are preferred, other reactionconditions which result in a significant reaction between collagen and amucopolysaccharide are also suitable.

While the coprecipitation method described above is preferred, collagenand GAGs can be reacted in other ways. The essential requirement is thatthe two materials be intimately contacted under conditions which allowthe GAGs to attach to the collagen chains. Another suitable technique isto coat collagen with GAGs, such as by dipping articles formed fromcollagen into a solution of GAG. A suitable variation of the lattertechnique involves prior coating with collagen of an article, sheet,film or tube fabricated from a non-collagenous material, such as asynthetic, natural or modified natural polymer, followed by dipping ofthe collagen-coated article, sheet, film or tube into the GAG solution.Still another suitable method is to intimately mix collagen with GAG,with each component in the form of a dry powder.

It will be clear that the collagen-GAG product prepared as describedabove can be formed into sheets, films, tubes and other shapes orparticles for its ultimate application.

To gain any significant increase in resistance to collagen resorption,it is necessary to have at least about 0.5% by weight of GAG bound tothe collagen chains. The upper limit may be set by the sites on collagenwhich are available for GAG attachment. For composites wherein the GAGis chondroitin 6-sulfate, levels of about 28% by weight have beenachieved; with hyaluronic acid, on the other hand, the upper limitachieved is about 25%.

Reaction with the GAGs also provides collagen with another valuableproperty, i.e., inability to provoke an immune reaction (foreign bodyreaction) from an animal host. To convert collagen into a materialwhich, when implanted, would not be recognized as a foreign bodyrequires reacting it with at least about 1% by weight of GAG.

Insolubility of the collagen-GAG products can be raised to the desireddegree by covalently cross-linking these materials. In general, anycovalent cross-linking method suitable for cross-linking collagen isalso suitable for cross-linking these composite materials. Such covalentcross-linking serves to prevent dissolution of mucopolysaccharide inaqueous solutions thereby making the materials useful for surgicalprostheses, etc.

Covalent cross-linking also serves to raise the resistance to resorptionof these materials. The exact function of cross-linking is notunderstood in this regard, but it may be that cross-linking anchors theGAG units to sites on the collagen chain which would normally beattacked by collagenase. Another possible explanation is thatcross-linking tightens up the network of collagen fibers and physicallyrestricts the diffusion of enzymes capable of degrading collagen.

It has been found that the cross-linked composites should have an M_(C)of between about 800 and about 60,000. Materials with M_(C) values belowabout 800 or above about 60,000 suffer significant losses in theirmechanical properties. Composites with an M_(C) of between about 5,000and about 10,000 appear to have a good balance of mechanical properties,and so this is the preferred range of cross-linking for productsrequiring such a balance of properties.

Covalent cross-linking can be achieved by many specific techniques withthe general categories being chemical, radiation and dehydrothermalmethods. An advantage to most cross-linking techniques contemplated,including glutaraldehyde cross-linking and dehydrothermal cross-linking,is that they also serve in preventing bacterial growth on the materials.Thus, the composites are being sterilized at the same time that they arecross-linked.

One suitable chemical method for covalently cross-linking thecollagen-GAG composites is known as aldehyde cross-linking. In thisprocess, the materials are contacted with aqueous solutions of aldehyde,which serve to cross-link the materials. Suitable aldehydes includeformaldehyde, glutaraldehyde and glyoxal. The preferred aldehyde isglutaraldehyde because it yields the desired level of cross-link densitymore rapidly than other aldehydes and also is capable of increasing thecross-link density to a relatively high level. Immersing the compositesin aldehyde solutions causes partial removal of the polysaccharidecomponent by dissolution thereby lessening the amount of polysaccharidein the final product. Unreacted aldehydes should be removed from thecollagen-GAG materials since residual aldehydes are quite toxic.

Other chemical techniques which are suitable include carbodiimidecoupling, azide coupling, and diisocyanate cross-linking.

A preferred cross-linking method is referred to herein as adehydrothermal process. In dehydrothermal cross-linking, it is notnecessary to add external cross-linking agents. The key is to dehydratethe product to be cross-linked to a moisture content of less than about1%. The amount of water which must be removed will vary with manyfactors, but, in general, sufficient water to achieve the desireddensity of cross-linking must be removed. Thus, the collagen-GAG productcan be subjected to elevated temperatures and/or vacuum conditions untilthe moisture content is reduced to extremely low levels. In the absenceof vacuum, temperatures above about 80° C., and preferably above 90° C.,can be used. At 23° C., a vacuum of at least about 10⁻⁵ mm Hg, andpreferably below 10⁻⁶ Hg, is suitable. Elevated temperature and vacuumcan be also used in combination; this, in fact, is the most expeditiousroute and is therefore preferred. With a vacuum of at least about 10⁻⁵mm Hg, it is preferred to use a temperature of at least about 35° C. Ingeneral, the materials are subjected to the elevated temperatures andvacuum conditions until the degree of insolubility desired is obtained.The higher the temperature, the lower is the vacuum required to arriveat a given cross-link density, and vice versa. A typical cross-linkingprocess to attain an M_(C) between about 5,000 and 10,000 involvessubjecting the collagen-GAG material to a temperature of 95° C. and avacuum of 0.01 mm Hg for 24 hours. This dehydrothermal cross-linkingprocess overcomes certain disadvantages of the aldehyde cross-linkingmethod and produces composites having relatively large amounts of GAGstrongly bound to the collagen chain.

Optimum mechanical properties are obtained for pure collagen materialswith M_(C), the average molecular weight between cross-links, between5,000 and 10,000. Certain collagen-GAG composites prepared by thedehydrothermal cross-linking process have superior elongation at break,strength, and toughness compared to collagen with similar values ofM_(C).

Based upon resistance to resorption, freedom from foreign body reaction,mechanical properties and blood-compatibility, cross-linked compositesshould contain at least about 0.5% bound GAG. Those compositescontaining between about 6% and about 15% of a sulfate-containing GAGare particularly preferred because of their outstanding properties,including blood-compatibility. The percentage of GAG specified herein isthat obtained when the measurement is made immediately aftercross-linking. With thorough washing, any GAG which is not covalentlybound can be removed.

When dry, the commercially available porous microcarriers contain about5 g of collagen per liter of bead internal volume. They exhibit about20% shrinkage by volume after hydration and suspension in phosphatebuffered saline (PBS). One gram of hydrated microcarriers in PBSoccupies a settled bed volume of about 250 ml. The material is roughly99.5% void volume. This makes it very efficient in terms of thepotential cell mass that can be grown per gram of microcarrier.

Particles are essentially spherical, with diameters of about 500 μm.Scanning electron microscopy shows pores of about 20 μm on the surfaceand 40 μm on the interior. The interior is made up of both fibrous andsheet-like structures, providing surfaces for cell attachment. The voidsinterconnect, providing access to the cells throughout the interior ofthe particle.

When suspended in PBS or culture medium, the microcarriers are nearlyneutrally buoyant. Small amounts of entrapped air or changes in solutiontemperature are sufficient to bias the particles toward floating orsinking. The spherical collagen-GAG material is precipitated in 70%ethanol to replace air in the beads with a liquid. The ethanol is thendisplaced with buffered saline or 30%-55% acetonitrile acidified withtrifluoroacetic acid (TFA) or other acids. Acetonitrile (ACN) is anorganic solvent, capable of denaturing proteins without affecting theirprimary structure. It is a common reagent in high performance liquidchromatography, and is used to elute proteins from silica based columnby perturbing hydrophobic interactions.

If the matrix material is to include osteogenic protein, the protein isadded in either Tris buffered saline (TBS) or acetonitrile/TFA is thenadded to the collagen-GAG material preequilibrated in the same buffer.The mixture is incubated at 4° C. and then lyophilized. This matrixmaterial may be made heavier by adding bovine insoluble collagen. Theresulting matrix material is a fine powder, insoluble in water, andcomprising nonadherent particles.

The matrix material preferably has the characteristics set forth belowin TABLE 1.

TABLE 1 Scanning Election Microscopy pore size 1-100 μ particle size74-420 μ pits <10³ nm Mercury Infusion Data pore size 2.390 ml/g bulkdensity 0.214 g/ml skeletal density 0.830 g/ml surface area 0.3226 g/mlpore area 0.214 m²/g pore diameter 41.988 μg

Practice of the invention requires the implantation of the matrix, e.g.,surgically, to serve as a template for bone formation in variousorthopedic, periodontal, and reconstructive procedures, or as acollagenous coating for implants. The matrix may be shaped as desired inanticipation of surgery or shaped by the physician or technician duringsurgery. The material may also be injected into a site where bone growthis desired.

Alternatively, the material may be coated or adsorbed on a prostheticimplant to promote implant/bone adhesion. Useful implants areconstructed of inert materials such as ceramic, metals such as titanium,cadmium, nickel, or cobalt, or polymers such as polyglycolic acid orpolylactic acid. Upon the addition of a heat-activated glue such asmethyl cellulose, the material becomes solidified after implantation orwhen placed at 37° C.

Thus, the material may be used for subcutaneous, intraperitoneal, orintramuscular implants; it may be shaped to span a non-union fracture orto fill a bone defect. The material encourages cell motility, cellularbiosynthetic functions, and cell division. Hence, osteoblasts may beinduced to migrate from viable bone to the material. In addition, thecross-linked GAG material has a negative surface charge which enhancescell attachment. Furthermore, osteoblasts synthesize fibronectin, acellular adherence protein that binds collagen, thereby enhancing theability of the migrating osteoblasts to adhere to the implant.

In bone formation procedures, the matrix material is slowly absorbed bythe body and is replaced by bone in the shape of or very nearly theshape of the implant. The matrix material also may be used to inducebone induction, and as a sustained release carrier.

The osteogenic device may comprise a shape-retaining solid made ofloosely adhered particulate material. It may also comprise a molded,porous solid, or simply an aggregation of close-packed particles held inplace by surrounding tissue. Insoluble collagen or inert polymers addedto the collagen-GAG-osteogenic protein particles may increase thedensity of the device. In addition, a glue or solidifying agentincluding methyl cellulose, (e.g., Methocel, Dow Chemical co.), may beadded. It is preferable to shape the matrix into the desired form of thenew bone or to have dimensions which span non-union defects.

The functioning of the various matrices prepared by any one of the abovemethods can be evaluated with an in vivo rat bioassay as described inthe patent applications referenced above. Briefly, the lyophilizedmatrix implant is placed into a subcutaneous wound which is then closedwith metallic clips. Implants are removed from the rat on day 12 afterimplantation and evaluated histologically for evidence of boneformation. FIG. 1 demonstrates that only mesenchymal cells will beassociated with a collagen-GAG implant that does not include osteogenicprotein, while FIG. 2 shows the ultimate development of endochondralbone in an implant which included osteogenic protein. Twelve dayimplants are usually sufficient to determine whether the implantscontain newly induced bone.

Alkaline phosphatase activity may be used as a marker for osteogenesis(Reddi et al. (1972) Proc. Natl. Acad. Sci. (U.S.A.) 69:1601-1605). Theenzyme activity may be determined spectrophotometrically afterhomogenization of the implant. The activity peaks at 9-10 days in vivoand thereafter slowly declines. Implants showing no bone development byhistology have little or no alkaline phosphatase activity under theseassay conditions. The assay is useful for quantitation and obtaining anestimate of bone formation quickly after the implants are removed fromthe rat.

Alternatively, the amount of bone formation can be determined bymeasuring the calcium content of the implant.

Such studies have established that the collagen-GAG particles are stillpresent after 12 days in vivo. As shown in FIG. 1 and in TABLE 2,control matrices without osteogenic protein did not induce bone growthin vivo; however, some mesenchymal cells recruited by the matrix werepresent. In comparison, collagen-GAG matrices, when formulated withosteogenic protein preparations in either TBS or acetonitrile/TFA,induced bone differentiation upon implantation as shown in FIG. 2 and inTABLE 2.

TABLE 2 Formula. Methods (+) Growth/# Samples % Bone GrowthAcetonitrile/TFA (+) OP 3/5 60 50 10 (−) OP 0/5 0 Tris-Buffer Saline (+)OP 3/3 80 70 10 (−) OP 0/3 0

Successful implants exhibit a controlled progression through the stagesof matrix induced endochondral bone development including: (1) transientinfiltration by polymorphonuclear leukocytes on day one; (2) mesenchymalcell migration and proliferation on days two and three; (3) chondrocyteappearance on days five and six; (4) cartilage matrix formation on dayseven; (5) cartiliage calcification on day eight; (6) vascular invasion,appearance of osteoblasts, and formation of new bone on days nine andten (see FIG. 2). If left beyond day 12 there is the appearance ofosteoblastic and bone remodeling and dissolution of the implanted matrixon days twelve to eighteen; and hematopoietic bone marrowdifferentiation in the ossicle on day twenty-one. The results show thatthe shape of the new bone substantially conforms to the shape of theimplanted matrix.

The collagen-GAG material is resorbed, making space for newly formedbone to occupy. The size of the bone formed is the size of the implantprepared. An implant is considered positive when the material islocalized at one site. Variation in response is explained bydifficulties in the implant procedure because of the low density of theprototype matrix material and difficulty in maintaining it at asubcutaneous site.

Details of how to make and how to use the materials of the invention aredisclosed below.

EXAMPLES A. Preparation of CollaQen-GAG Matrix

The cross-linked collagen-GAG material is prepared by previouslypublished procedures of Yannas. (U.S. Pat. No. 4,350,629). Briefly thisentails the following procedures.

1. Preparation of the Collagen

Bovine collagen is prepared by the methods of Komanowsky et al. (J.Amer. Leather Chemists Assn. (1974) 69:410-422). 0.55 g of freeze-driedcollagen is ground in a Wiley mill (A. H. Thomas Co., Phila. PA) to a 60mesh particle size. It is added to 200 ml of 0.05 M aqueous acetic acid.This solution is stirred for 60 minutes in an ice-jacketed blender(Eberbach Corp., Ann Arbor, Mich.) on a 2-speed power unit (Waring Co.,Hartford, Conn.) set on high speed with the line voltage reduced to 60volts. Following this blending step, the solution is placed in a tightlyclosed glass jar and the collagen is allowed to swell for 72 hours at 4°C.

2. Preparation of Collagen-Chondroitin 6-Sulfate Coprecipitates

Collagen 0.3% (wt/vol) dispersed in 0.05 M acetic acid is thoroughlyagitated with a Teflon stirrer at 23° C. While the dispersion wasmixing, 1% chondroitin 6-sulfate (wt/vol) in 0.05 M acetic acid pH 3.2is added dropwise from a buret at the rate of about 0.1 ml per second.The addition of chondroitin 6-sulfate causes collagen to coprecipitateforming a tangled mass of collagen fibrils coated with GAG. When 90% byweight of collagen is coprecipitated in this manner with 10% by weightchondroitin 6-sulfate, a systematic mass balance shows that about 95% ofthe added chondroitin 6-sulfate is coprecipitated.

After coprecipitation, the tangled mass of fibrils is homogenized in aWaring Blender until the fibrils are about 1 mm in length. The mixtureof fibrils in 0.05 M acetic acid separates into two phases when leftunagitated for more than five minutes, so that mixing is required beforefiltration. Filtration is performed by filtering thecollagen-mucopolysaccharide dispersion under vacuum through a Buchnerfunnel containing Schleicher and Schuell (Keene, New Hampshire) filterpaper No. 576. The coprecipitate is allowed to dehydrate underatmospheric conditions until the moisture content was about 20% byweight.

If it is desirable to maintain high porosity in the product, thecomposites can be freeze dried. Typical conditions are a temperature of−50° C. and a vacuum of 0.06 mm Hg.

3. Aldehyde Cross-linking

Method A

Coprecipitated collagen-chondroitin 6-sulfate as prepared in EXAMPLE 2is covalently cross-linked by immersing it in a 0.02 M solution ofglutaraldehyde. This treatment effectively immobilizes a fraction of thepolysaccharide component on the collagen fibrils or molecules.Cross-linking is evidenced by the inability to remove the polysaccharidefrom the aldehyde-treated film by prolonged washing with a phosphatebuffer solution containing 0.4 M sodium chloride, pH 7.4, which is awell known solvent of chondroitin 6-sulfate. Unreacted aldehydes areremoved by treatment with a solution of 5,5 dimethyl-1,3-cyclohexanedione (dimedone). Evaporation of the water leaves behind a filmcontaining up to about 10% by weight polysaccharide.

Method B

A solution of 25% glutaraldehyde (“Baker-analyzed” reagent grade, J. T.Baker Co., Philadelphia, Pa.) in distilled water is prepared. Asufficient quantity of thins solution is added to the acidic collagensolution to comprise 0.5% (vol/vol) glutaraldehyde. The glutaraldehydesolution is added while the dispersion was blended for one hour in anoverhead blender (Hamilton Beach Div. of Scovill, Washington, N.C.) seton the low speed with the line voltage reduced to 60 volts.

0.0578 g chondroitin 6-sulfate is dissolved in 10 ml of 0.05 M aceticacid. This solution is added to 175 ml of the glutaraldehyde-treatedcollagen dispersion. The addition is performed over a period of 5minutes while the dispersion is being blended in the overhead blender.

Shortly thereafter, the dispersion is filtered in a Buechner funnel.This filtering step is completed in about 20 minutes. The resulting wetmembrane is then air-dried and milled to a 60 mesh particle size. It isdispersed in physiological saline solution (0.15 M NaCl, pH 7).

4. Dehydrothermal Cross-linking

The product of EXAMPLE 3 is placed in a vacuum oven and exposed to atemperature of 115° C. and a vacuum of at least 0.3 mm Hg for 48 hours.At the end of this treatment, less than 10 weight percent of thepolysaccharide originally incorporated into the film can be removed by48-hour immersion in distilled water, a solvent for chondroitin6-sulfate.

B. Preparation of Osteogenic Material

The osteogenic protein may be obtained using the methods disclosed inU.S. patent application Ser. No. 179,406 filed Apr. 8, 1988; PCTapplication No. US89/01469 (entitled “Biosynthetic Osteogenic Proteinsand Osteogenic Devices Containing Them”), and PCT Application No.US89/01453, (entitled Osteogenic Devices). Both PCT applications werefiled Apr. 7, 1989. Alternatively, extracts rich in osteogenic proteinuseful in fabricating devices may be obtained as disclosed in U.S. Pat.No. 4,294,753 to Urist.

C. Formulation of Osteogenic Protein within the Collagen-GAG Material

The collagen-GAG material assuming the form of small beads is expandedin 70% ethanol to replace air in the beads with a liquid. The beads areprepared as follows: about 100 ml of 70% ethanol (vol/vol) in sterilewater is added to a 50 ml bottle of collagen-GAG beads (BiomatCorporation, Belmont, Mass.). The beads are allowed to settle at 4° C.The top layer of ethanol is decanted and replaced with fresh 70%. Thisstep is repeated until all of the particles have sunk. Alternatively,the particles may be prepared by centrifugation at low speed (e.g. ×500g).

The 70% ethanol is then displaced from the beads by 50 mm Tris-HCl, 0.15M NaCl, pH 7.0 (TBS), or by 30% to 50% acetonitrile containing 0.1%trifluoroacetic acid (TFA). The displacement of ethanol with buffer isaccomplished by repeated slow-speed centrifugation, decanting, andexchanging buffers. This is done at 4° C. to aid in the preparationprocess and to avoid possible degradation of the collagen-GAG material.

Osteogenic protein is then adhered to the matrix material. Theosteogenic protein preparations adhered to the matrix material are (1)the sephacryl active fraction (this fraction induces bone growth in ratat 5 to 20 μg/implant); and (2) the heparin-sepharose fraction (thisfraction induces bone in rat at 1 to 10 μg/implant). The osteogenicprotein may be formulated onto the collagen-GAG matrix by.one of thefollowing methods:

1. Acetonitrile/TFA Lyophilization

To 0.2-0.3 ml of matrix preequilibrated with acetonitrile/TFA buffer isadded 200 pl of osteogenic protein fractions in 50% acetonitrilecontaining 0.1% TFA. The mixture is incubated at 4° C. for 16 hours. Itis then lyophilized.

2. TBS Binding/Lyophilization

To 0.2-0.3 ml of matrix equilibrated with TBS buffer is added 200 pl ofTBS buffer. 10 μl of 50% acetonitrile containing 0.1% TFA, whichcontains osteogenic protein preparation in a concentrated amount isadded. The pH should then be adjusted to 7.0. This mixture is incubatedat 24° C. for 2 hours and then 4° C. for 16 hours before lyophilization.

D. Bioassay for Bone Induction

The bioassay for bone induction as described by Sampath and Reddi (Proc.Natl. Acad. Sci. USA (1983) 80: 6591-6595), herein incorporated byreference, may be used to monitor endochondral bone differentiationactivity. This assay consists of implanting the bovine test samplesxenogenically in subcutaneous sites in recipient rats under etheranesthesia. Male Long-Evans rats, aged 28-32 days, were used. A verticalincision (1 cm) is made under sterile conditions in the skin over thethoraic region, and a pocket is prepared by blunt dissection.Approximately 25 mg of the test sample is implanted deep into the pocketand the incision is closed with a metallic skin clip. The heterotropicsite allows for the study of bone induction without the possibleambiguities resulting from the use of orthotopic sites. The day ofimplantation is designated as day one of the experiment.

Implants are removed from the rat on day 12 after implantation andevaluated histologically for evidence of bone formation.

E. Histology

Resected implants are fixed in Bouins Solution, embedded in paraffin,cut into 6-8 mm sections, and stained with toluidine blue orhemotoxylin/eosin.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The presentembodiments are therefore to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims rather than by the foregoingdescription, and all changes which come within the meaning and range ofequivalency of the claims are therefore intended to be embraced therein.

What is claimed is:
 1. An osteogenic device for inducing local bone orcartilage formation in a mammal, said device comprising: (a)biocompatible, synthetic, porous matrix, said matrix comprising apolymer of collagen and glycosaminoglycan crosslinked ex vivo to anM_(C) value of about 800 to about 60,000 and comprising greater than 1%by weight of said glycosaminoglycan; (b) osteogenic protein capable ofinducing endochondral bone formation in a mammal dispersed within saidmatrix; and (c) solidifying agent.
 2. The device of claim 1, whereinsaid solidifying agent solidifies at a temperature greater than ambienttemperature.
 3. The device of claim 1, wherein said solidifying agent ismethyl cellulose.
 4. The device of claim 1, wherein said osteogenicprotein is OP-1.
 5. The device of claim 1, wherein saidglycosaminoglycan comprises at least 5% by weight of said polymer. 6.The device of claim 5, wherein said glycosaminoglycan comprises fromabout 6% to about 15% by weight of said polymer.
 7. The device of claim1, wherein said glycosaminoglycan is selected from the group consistingof chondroitin 4-sulfate, chondroitin 6-sulfate, hyaluronic acid,dermatan sulfate, keratan sulfate, heparin, heparan sulfate, andcombinations thereof.
 8. The device of claim 1, wherein saidglycosaminoglycan comprises a sulfate group.
 9. The device of claim 1,wherein said glycosaminoglycan comprises chondroitin 6-sulfate.
 10. Thedevice of claim 1, wherein said polymer is cross-linked to an M_(C)value of between 5,000 and 10,000.
 11. The device of claim 1, whereinsaid osteogenic protein comprises a pair of polypeptide chains disulfidebonded to form a dimeric species and further wherein each of saidpolypeptide chains is characterized as having at least seven cysteineresidues in the same relative positions as the seven cysteine skeletonsequence: 1       10        20        30        40CXXXXLXVXFXDXGWXXWXXXPXGXXAXYCXGXCXXPXXX        50        60         70       80XXXXXNHAXXQXXVXXXNXXXXPXXCCXPXXXXXXXXLXX         90      100XXXXXVXLXXYXXMXVXXCX

wherein each said X is an amino acid, such that said osteogenic proteininduces local bone or cartilage formation in a mammal when disposedwithin said matrix implanted in said mammal.
 12. The device of claim 1,wherein said osteogenic protein comprises a pair of polypeptide chainsdisulfide bonded to form a dimeric species and further wherein each ofsaid polypeptide chains is characterized as having at least six cysteineresidues in the same relative positions as the six cysteine skeletonsequence: 1        10       20        30          40     LXVXFXDXGWXXWXXXPXGXXAXYCXGXCXXPXXX             50        60        70     XXXXXNHAXXQXXVXXXNXXXXPXXCCXPXXXXXX          80        90       100     XXLXXXXXXXVXLXXYXXMXVXXCXCX,

wherein each said X is an amino acid, such that said osteogenic proteininduces local bone or cartilage formation in a mammal when disposedwithin said matrix implanted in said mammal.
 13. The device of claim 1,wherein said osteogenic protein comprises a pair of subunitsconstituting a dimer under oxidizing conditions, one of said subunitshaving an amino acid sequence comprising the amino acid sequence, orconservative amino acid substituted variants thereof,1       10        20        30        40        50STGSKQRSQNRSKTPKNQEALRMANVAENSSSDQRQACKKHELYVSFRDL        60        70        80        90       100GWQDWIIAPEGYARYYCEGECAFPLNSYMNATNHAIVQTLVHFINPETVP       110        120      130 KPCCAPTQLNAISVLYFDDSSNVILKKYRNMVVRACGCH

such that said subunit, when in combination with the second of saidsubunits, induces local bone or cartilage formation in a mammal whendisposed within said matrix implanted in said mammal.
 14. The device ofclaim 1, wherein said polymer is selected from the group consisting ofType I collagen, Type II collagen, and mixtures thereof.
 15. The deviceof claim 1, wherein said osteogenic protein comprises a pair of subunitsconstituting a dimer under oxidizing conditions, one of said subunitshaving an amino acid sequence sufficiently duplicative of the amino acidsequence of OP1: 1       10        20        30        40STGSKQRSQNRSKTPKNQEALRMANVAENSSSDQRQACKK         50       60        70        80HELYVSFRDLGWQDWIIAPEGYARYYCEGECAFPLNSYMN        90       100       110        120ATNHAIVQTLVHFINPETVPKPCCAPTQLNAISVLYFDDSS        130 NVILKKYRNMVVRACGCH

such that said subunit, when in combination with the second of saidsubunits, induces local bone or cartilage formation in a mammal whendisposed within said matrix implanted in said mammal.